Download Fabricator Generation III Manual

FABRICATOR
250C III
320C III
320S III C/W VFE 4C III
400S III C/W VFE 4C III
500S III C/W VFE 4C HS III
MIG Power Supplies
Operation Manual
Version No:
AW-02
Issue Date: July 13th, 2012
Operating Features
250
AMP
320
AMP
400
AMP
500
AMP
CC
DC
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc product. We are proud to
have you as our customer and will strive to provide you with the
best service and reliability in the industry. This product is backed by
our extensive warranty and world-wide service network. To locate
your nearest distributor or service agency call Thermadyne
Customer Service on (44) 01257 224824.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Arc product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid
potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is a Global Brand of Arc Welding Products for
Thermadyne Industries. We manufacture and supply to major
welding industry sectors worldwide including; Manufacturing,
Construction, Mining, Automotive, Aerospace, Engineering, Rural
and DIY/Hobbyist.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.
WARNINGS
__________________________________________________________
Read and understand this entire Manual and your employer’s safety
practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the
Manufacturer's best judgement, the Manufacturer assumes no
liability for its use.
Fabricator 250C III MIG Welding Machine, Part Number - FAB250C
Fabricator 320C III MIG Welding Machine, Part Number - FAB320C
Fabricator 320S III MIG Welding Machine, Part Number - FAB320S
Fabricator 400S III MIG Welding Machine, Part Number - FAB400S
Fabricator 500S III MIG Welding Machine, Part Number - FAB500S
Published by:
Thermadyne Industries Ltd
Chorley North Industrial Park
Chorley
Lancashire
PR6 7BX
England
www.thermadyne.com
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage
caused by any error or omission in this Manual, whether such error results from negligence, accident, or
any other cause.
Publication Date: March 1th, 2012
Record the following information for Warranty purposes:
Where Purchased:
___________________________________
Purchase Date:
___________________________________
Equipment Serial #:
___________________________________
TABLE OF CONTENTS
SECTION 1:
1.01
1.02
1.03
1.04
SAFETY PRECAUTIONS
Safety Instructions and Warning
Declaration of Conformity
Statement of Warranty
Symbol Legend
1
1
5
6
7
SECTION 2:
2.01
2.02
2.03
2.04
2.05
2.06
2.07
2.08
2.09
INTRODUCTION AND DESCRIPTION
How to use this Manual
Equipment Identification
Receipt of Equipment
Description
Safety
Transporting Methods
Protected Filter Lenses
User Responsibility
Duty Cycle
8
8
8
8
9
9
9
9
10
10
SECTION 3:
3.01
3.02
3.03
3.04
3.05
3.06
INSTALLATION RECOMMENDATIONS
Environment
Location
Electrical Input Connections
Electrical Input Requirements
Input Power
Specifications
11
11
11
11
12
13
14
SECTION 4:
4.01
4.02
4.03
OPERATOR CONTROLS
Fabricator Layout 250C & 320C
Fabricator Layout 320S & 400S
Fabricator Layout 500S
16
16
18
22
SECTION 5:
5.01
5.02
5.03
5.04
5.05
5.06
5.05
UNDERSTANDING AND SETTING UP FOR WELDING
Power Source Features
Basic Control Panel - Overview
Digital Control Panel - Overview
Digital Control Panel - Description
Wire Feeder Motor & Feedroll Assembly
Wire Feed Rollers
Spool holder description
25
25
26
27
28
30
31
31
SECTION 6:
6.01
6.02
6.03
6.04
6.05
6.06
6.07
6.08
GETTING STARTED
Torch Connection
How to connect the work lead
Where to connect the work clamp
How to connect to the mains
How to fit the wire spool
Inserting the wire
How to connect the gas cylinder
How to configure the machine for aluminium welding
32
32
32
32
33
33
33
35
35
SECTION 7:
7.01
7.02
7.03
7.04
7.05
7.06
OPERATION
Setting welding current and voltage
Welding modes
Secondary parameters
Two stroke
Four stroke
Spot and stitch welding
36
36
36
36
37
37
38
SECTION 8:
8.01
8.02
8.03
8.04
8.05
8.06
8.07
BASIC WELDING TECHNIQUE
Setting of the Power Source
Position of MIG Torch
Distance of the MIG Torch Nozzle to the Work Piece
Travel Speed
Electrode Wire Size Selection
Stitch Welding Operation
Spot Welding Operation
39
39
39
39
39
39
40
40
SECTION 9:
ROUTINE MAINTENANCE & INSPECTION
41
SECTION 10:
10.01
10.02
10.03
10.04
BASIC TROUBLESHOOTING
Porosity
Inconsistent wire feed
Welding Problems
Power Source Problems
42
42
43
44
45
SECTION 11:
11.01
11.01
11.02
11.02
11.03
11.04
11.04
11.05
11.06
SPARE PARTS
Parts description Fabricator 250C & 320C
Spare part numbers Fabricator 250C & 320C
Parts description Fabricator 320S & 400S
Spare part numbers Fabricator 320S & 400S
VFE 4C WFU Description + Spare Part Numbers
Parts description Fabricator 500S
Spare part numbers Fabricator 500S
VFE 4C HS WFU Description + Spare Part Numbers
Water Cooler Parts Description + Spare Parts List
48
48
49
51
52
54
56
57
59
61
SECTION 12:
12.01
12.02
12.03
12.04
MACHINE SCHEMATICS
Schematic for the FAB 250C & 320C
Schematic for the FAB 320S & 400S
Schematic for the FAB 500S
Wire Feed Unit Schematic
62
62
63
64
65
SECTION 13:
Optional accessories
66
Figures Description
Figure No
Description
Figure 1
Colour Picture of Fabricator Family
Front page
Figure 2
Symbol Legend
7
Figure 3
Electrical Input Connections
12
Figure 4
Figure 5
Figure 6
Fabricator Layout 250III / 320 Compact
Fabricator Layout 320III / 400III Seperate
Fabricator Layout 500III Seperate
16
18
22
Figure 7
Basic Control Panel - Overview
26
Figure 8
Digital Control Panel - Overview
27
Figure 9
Digital Control Panel Description
28
Figure 10
Wire Feed Motor Assembly - 2 & 4 Roll
30
Figure 11
Figure 12
Feed Roll Rollers Information
31
Spool Holder Description
31
Figure 13
Torch Connection
32
Figure 14
Connection of Work Lead
32
Figure 15
Connection on Work Clamp
33
Figure 16
Spool Holder Description
33
Figure 17
Wire Feed Description
34
Figure 18
Pressure Roll Tension
34
Figure 19
Aluminium Liner Information
35
Figure 20
Two Stroke Description
37
Figure 21
Four Stroke Description
37
Figure 22
Spot & Stitch Description
38
Figure 23
Spot & Stitch Description
38
Figure 24
Position of MIG Torch
39
Figure 25
Wire Size Penetration Comparison
40
Figure 26
Parts Description Fab 250C & 320C
48
Figure 27
Parts Description Fab 320S & 400S
51
Figure 28
VFE 4C III W.F.U. Parts Description + Spare Part No
54
Figure 29
Parts Description Fab 500S
56
Figure 30
VFE 4C 4S III W.F.U. Parts Description + Spare Part No
59
Figure 31
Water Cooler Parts description + Spare Parts List
61
Figure 32
Power Source Schematic for Fab 250C & 320C
62
Figure 33
Power Source Schematic for Fab 320S & 400S
63
Figure 34
Power Source Schematic for Fab 500S
64
Figure 35
Wire Feed Unit Schematic
65
SECTION 1: Safety Instructions and Warnings
WARNING
ARC WELDING can be hazardous.
Protect yourself and others from possible serious injury or death. Keep children away. Pace maker wearers keep away until
consulting your doctor. Do not lose these instructions. Read operating / instruction manual before installing, operating or
servicing this equipment.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not
strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld. Certain
practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
Safe practices are out lined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other
guides to what you should learn before operating this equipment are listed at the end of these safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine terminal
circuits are also live when power is on. In
semiautomatic or automatic wire welding, the wire,
wire reel, drive roll housing, and all metal parts touching the welding
wire are electrically live. Incorrectly installed or improperly grounded
equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating
mats or covers.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch
open, or remove line fuses so power cannot be turned on
accidentally.
5. Properly install and ground this equipment according to its
Owner's Manual and national, state, and 10 cal codes.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
1.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
hearing.
2.
3.
4.
5.
Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
Do not use worn, damaged, under sized or poorly spliced cables.
Do not wrap cables around your body.
Ground the workpiece to a good electrical (earth) ground.
Do not touch electrode while in contact with the work (ground)
circuit.
Use only well-maintained equipment. Repair or replace damaged
parts at once.
In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
Wear a safety harness to prevent falling if working above floor
level.
Keep all panels and covers securely in place.
Wear a welding helmet fitted with a proper shade of filter (see
ANSI 249.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
Wear approved safety glasses. Side shields recommended.
Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
Use approved earplugs or earmuffs if noise level is high.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A 8.2-73
Welding or Cutting
operation
Electrode size Metal Thickness or
Welding Current
Torch soldering
All
Torch brazing
All
Oxygen cutting
Light
Under 1 in., 25 mm
Medium
1 – 6 in., 25 – 150 mm
Heavy
Over 6 in., 150 mm
Gas welding
Light
Under 1/8 in., 3 mm
Medium
1/8 – 1/2 in., 3 – 12 mm
Heavy
Over 1/2 in., 12 mm
Shielded metal-arc welding (stick) electrodes
Under 5/32 in., 4 mm
Under 5/32 to ¼ in., 4 to 6.4mm
Over ¼ in., 6.4 mm
Filter
shade
no.
2
2 or 3
3 or 4
4 or 5
5 or 6
4 or 5
5 or 6
6 or 8
10
12
14
1
Welding or Cutting operation
Gas metal arc welding
Non Ferrous base metal
Ferrous base metal
Gas tungsten arc welding (TIG)
Atomic Hydrogen welding
Carbon Arc welding
Plasma arc Welding
Carbon Arc Gouging
Light
Heavy
Plasma arc cutting
Light
Medium
Heavy
Electrode size Metal
Filter
Thickness or Welding shade no.
Current
All
All
All
All
All
All
11
12
12
12
12
12
12
14
Under 300 Amp
300 to 400 Amp
Over 400 Amp
9
12
14
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not
breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDS) and the
manufacturer's instruction for metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapours to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized lead, or
cadmium plated steel, unless the coating is re moved from the
weld area, the area is well ventilated, and if necessary, while
wearing an air supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot work
piece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding
wire to metal objects can cause sparks, over
heating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material
Remove all flammables within 35ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Flying sparks and hot metal can
cause Injury
3. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
4. Watch for fire, and keep a fire extinguisher nearby.
5. Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
6. Do not weld on closed containers such as tanks or drums.
7. Connect work cable to the work as close to the welding area as
practical to prevent welding current from travelling long, possibly
unknown paths and causing electric shock and fire hazards.
8. Do not use welder to thaw frozen pipes.
9. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefuIIy.
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining them
to a stationary support or equipment cylinder rack to prevent falling
or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
WARNING
ENGINES can be dangerous.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away from
any building air intakes.
2
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable
3. Allow engine to cool before fuelling. If possible, check and add fuel
to cold engine before beginning job.
1. Stop engine before checking or adding fuel.
4. Do not overfill tank - allow room for fuel to expand away from any
2. Do not add fuel while smoking or if unit is near
building air intakes.
any sparks or open flames.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards
closed and securely in place.
2. Stop engine before installing or connecting unit.
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes
and skin.
Batteries contain acid and generate explosive gases
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and under
pressure
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Re-install panels or guards and close doors when servicing is
finished and before starting engine.
1.
2.
3.
4.
Always wear a face shield when working on a battery.
Stop engine before disconnecting or connecting battery cables.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
NOTE: Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields
To reduce magnetic fields in the work place, use the following procedures:
1. Keep cables close together by twisting or taping them.
2. Do not coil or drape cables around the body.
3. Arrange cables to one side and away from the operator.
4. Keep welding power source and cables as far away from body as
practical.
About Pacemakers: The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for
complete information.
3
Page left blank intentionally
4
1.02 DECLARATION OF CONFORMITY
Manufacturer and Merchandiser of Quality Consumables and Equipment:
Address:
Thermal Arc
Thermadyne Europe
Europa Building
Chorley North Industrial Park
Chorley
Lancashire
England
PR6 7BX
Description of equipment:
Welding Equipment (GMAW) Thermal Arc Fabricator 250C III, 320CIII, 320S III, 400S III
& 500S III and associated accessories.
The equipment described in this manual conforms to all applicable aspects and regulations
of the “Low Voltage Legislation“ (Low Voltage Directive (LVD) 2006/95/EC ) and to the National
legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of
the “Electromagnetic Compatibility (EMC) Legislation” (Directive 2004/108/EC) and to the
National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts
used to manufacture a unit and date of manufacture.
National Standard and Technical Specifications:
The product is designed and manufactured to a number of standards and technical requirements.
Among them are:
• CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
• ISO/IEC.60974-1 (BS.638-PT10) (EN.60.974-1) (EN50192) (EN50078) applicable to welding
equipment and associatedaccessories.
• For environments with increased hazard of electrical shock, Power Supplies bearing the
'S' mark conform to EN50192 when used in conjunction with hand torches with exposed cutting
tips, if equipped with properly installed standoff guides.
• Extensive product design verificatio is conducted at the manufacturing facility as part of the
routine design and manufacturing process. This is to ensure the product is safe, when used
according to instructions in this manual and related industry standards, and performs as
specifed. Rigorous testing is incorporated into the manufacturing process to ensure the
manufactured product meets or exceeds all design specifications.
Thermadyne has been manufacturing products for more than 30 years, and will continue to
achieve excellence in our area of manufacture.
Manufacturers responsible representative:
Steve Ward
Operations Director,
Thermadyne Europe,
Europa Building,
Chorley N Industrial Park,
Chorley, Lancashire,
England, PR6 7BX.
5
1.03 STATEMENT OF WARRANTY
In accordance with the warranty periods stated below, Thermadyne guarantees the proposed
product to be free from defects in material or workmanship when operated in accordance with the
written instructions as defined in this operating manual.
Thermadyne welding products are manufactured for use by commercial and industrial users and
trained personnel with experience in the use and maintenance of electrical welding and cutting
equipment.
Thermadyne will repair or replace, at its discretion, any warranted parts or components that fail due
to defects in material or workmanship within the warranty period. The warranty period begins on
the date of sale to the end user.
Thermal Arc Fabricator 250C III, 320C III, 320S III, 400S III & 500S III
Component
Warranty Period
Power Source
Wire Feed Unit
Optional Cooler
2 Years
2 Years
2 Years
If warranty is being sought, Please contact your Thermadyne product supplier for the warranty
repair procedure.
Thermadyne warranty will not apply to:
•
•
•
•
•
Equipment that has been modified by any other party other than Thermadyne’s own service
personnel or with prior written consent obtained from Thermadyne Service Department.
Equipment that has been used beyond the specifications established in the operating
manual.
Installation not in accordance with the installation/operating manual.
Any product that has been subjected to abuse, misuse, negligence or accident.
Failure to clean and maintain (including lack of lubrication, maintenance and protection),
the machine as set forth in the operating, installation or service manual.
Within this operating manual are details regarding the maintenance necessary to ensure trouble
free operation.
This manual also offers basic troubleshooting, operational and technical details including
application usage.
You may also wish to visit our web site www.thermadyne.com select your product class and then
select literature. Here you will find documentation including:
•
•
•
Operator manuals
Service manuals
Product guides
Alternatively please contact your Thermadyne distributor and speak with a technical
representative.
NOTE
Warranty repairs must be performed by either a Thermadyne Service Centre, a Thermadyne
distributor or an Authorised Service Agent approved by the Company
January 2012
6
1.04 SYMBOL LEGEND
Figure 2.
7
SECTION 2: INTRODUCTION AND DESCRIPTION
2.01 How to use this Manual
This Operator owner’s manual applies to Part Numbers: FAB250C III, FAB320CIII,
FAB320S III, FAB400S III & FAB500S III
To ensure safe operation, read the entire manual, including the chapter on safety
instructions and warnings. Throughout this manual, the words WARNING, CAUTION,
and NOTE may appear. Pay particular attention to the information provided under
these headings. These special annotations are easily recognized as follows:
WARNING
A WARNING gives information regarding possible personal injury
CAUTION
A CAUTION refers to possible equipment damage
NOTE
A NOTE offers helpful information concerning certain operating procedures
Additional copies of this manual may be purchased by contacting Thermal Arc at the
address and phone number given below:
Thermadyne Customer Service
Thermadyne Industries Ltd
Europa Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7BX.
Phone: (44) 01257 261755
Fax: (44) 01257 224842
Include the Owner’s Manual number and equipment identification numbers.
Electronic copies of this manual can also be emailed to you at no charge in
Acrobat PDF format by contacting Thermadyne Customer Service on (44) 01257 261755.
2.02 Equipment Identification
The unit’s identification number (specification or part number), model, and serial
number appear on a nameplate fixed to the rear panel. In some cases, equipment
which does not have a control panel such as gun and cable assemblies is identified
only by the specification or part number printed on the shipping container.
Record the number for future reference.
2.03 Receipt of Equipment
When you receive the equipment, check it against the invoice to make sure it is
complete and inspect the equipment for possible damage due to shipping. If there is
any damage, notify the carrier immediately to file a claim.
Furnish complete information concerning damage claims or shipping errors to the
distributor you purchased the equipment from.
Include all equipment identification numbers as described above along with a full
description of the parts in error.
Move the equipment to the installation site before unpacking the unit. Use care to
avoid damaging the equipment when using bars, hammers, etc, to unpack the unit.
8
2.04 Description
The Thermal Arc Fabricators are 400Volt 3 phase MIG machines which offer great
performance, A 250A & 320Amp option also a 420Amp output @ 30% duty cycle unit and
a 530Amp maximum output @ 25% duty cycle with 30 voltage steps along with separate
WFU's, digital meters and cylinder racks. The wire feed unit system has an option of up to
10m interconnection cables. The Wirefeeder has touch panel control pad incorporating
spot/stitch timers. The Wirefeeder also benefits from fitted wheels and conveniently
fits on a swivel mount on top of the power source or can be lifted off the pivot and
carried up on top of equipment or machinery up to 10m away. The Thermal Arc
Fabricator range are extremely versatile all round performers that offer excellent
performance on mild steel, stainless steel, aluminium, silicon bronze and some hard
facing wires with Argon based shielding gases. The Fabricators also gives excellent
results on mild steel using Carbon Dioxide shielding gas.
The following instructions detail how to correctly set up the welder and give guidelines
on gaining the best production efficiency from the Fabricator. Please read these
instructions thoroughly before using your Fabricator welder.
2.05 Safety
The following basic safety rules should always be followed:
• Ensure the machine is correctly installed, if necessary, by a qualified
electrician.
• Ensure the Power Supply is grounded correctly (electrically) in accordance with
local regulations.
• Excessive heat in the welding cables may cause fire. Never weld with poor
electrical connections, damaged welding cables or exceed the welding cable
current rating as this will produce excessive heat and may cause a fire.
• Always wear the correct protective clothing for protection from sparks, molten
particles and arc rays.
• When welding in confined spaces, always ensure adequate ventilation and
constant observation of the operator.
• Keep combustible materials away from the welding area. Have a suitable fire
extinguisher close by.
• Never watch the welding arc with naked eyes. Always use and wear a welding
mask fitted with the correct filter lens.
• Do not stand on damp ground when welding. For more complete safety advice
please read section 1.
2.06 Transporting Methods
These units are equipped with handles mounted on the front panel of power source.
If using a fork lift vehicle, place and secure unit on a suitable pallet before transporting.
If using an overhead crane, ensure correct slings are used before lifting.
2.07 Protective Filter Lenses
Protective filter lenses are provided to reduce the intensity of radiation entering the
eye thus filtering out harmful infrared, ultraviolet radiation and a percentage of the
visible light. Such filter lenses are incorporated within face shields. To prevent damage
to the filter lenses from molten or hard particles an additional hard clear glass or
special plastic external cover lens should be used. This cover lens should always be
kept in place and replaced before the damage impairs your vision while welding.
9
Approximate range of welding current
Up to 150
150-250
250-300
300-350
Over 350
Filter lens required for MIG
Shade 10
Shade 11
Shade 12
Shade 13
Shade 14
2.08 User Responsibility
This equipment will perform as per the information contained herein when installed,
operated, maintained and repaired in accordance with the instructions provided. This
equipment must be checked periodically. Defective equipment (including welding
leads) should not be used. Parts that are broken, missing, plainly worn, distorted or
contaminated, should be replaced immediately. Should such repairs or replacements
become necessary, it is recommended that such repairs be carried out by
appropriately qualified persons approved by Thermal Arc. Advice in this regard can be
obtained by contacting Thermal Arc.
This equipment or any of its parts should not be altered from standard specification
without prior written approval of Thermal Arc. The purchaser of this equipment shall
have the sole responsibility for any malfunction which results from improper use or
unauthorized modification from standard specification, faulty maintenance, damage or
improper repair by anyone other than appropriately qualified persons approve by
Thermal Arc.
2.09 Duty Cycle
The rated duty cycle of a welding Power Supply is the operating time it may be used at
its rated output current without exceeding the temperature limits of the insulation of the
component parts. To explain the ten minute duty cycle period the following example is
used. Suppose a welding Power Supply is designed to operate at 50% duty cycle, 250
amperes at 28 volts. This means that it has been designed and built to provide the
rated amperage (250A) at the rated load voltage (28V), for 5.0 minutes out of every 10
minute period (50% of 10 minutes is 5.0 minutes). During the other 5.0 minutes of the
10 minute period the Power Supply must idle and be allowed to cool. The thermal cut
out will operate if the duty cycle is exceeded.
WARNING
ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input
power conductors from de-energized supply line before moving the welding power
source.
WARNING
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
10
SECTION 3: INSTALLATION RECOMMENDATIONS
3.01 Environment
The Fabricator 250C III, 320C/S III, 400S III & Fabricator 500S III are NOT designed
for use in environments with increased hazard of electric shock.
Examples of environments with increased hazard of electric shock are:• Locations in which freedom of movement is restricted, so that the operator is
forced to perform the work in a cramped (kneeling, sitting or lying) position with
physical contact with conductive parts.
• Locations which are fully or partially limited by conductive elements, and in
which there is a high risk of unavoidable or accidental contact by the operator.
• Wet or damp hot locations where humidity or perspiration considerably
reduces the skin resistance of the human body and the insulation properties of
accessories.
3.02 Location
Be sure to locate the welder according to the following guidelines:
• In areas, free from moisture and dust.
• Ambient temperature between 0 degrees C and 40 degrees C.
• In areas, free from oil, steam and corrosive gases.
• In areas, not subjected to abnormal corrosive gases, vibration or shock.
• In areas, not exposed to direct sunlight or rain.
• Place at a distance of 300mm or more from the walls or similar that could
restrict natural air flow for cooling.
• The minimum ground clearance for these products is 130mm.
WARNING
Thermal Arc advises that this equipment be electrically connected by a qualified electrician.
3.03 Electrical Input Connections
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input
power.
DO NOT TOUCH live electrical parts
SHUT DOWN welding power source, disconnect input power employing
lockout/tagging procedures.
Lockout/tagging procedures consist of padlocking line disconnect switch in open
position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker
or other disconnecting device.
11
3.04 Electrical Input Requirements
Operate the welding power source only from a three-phase 50/60 Hz, AC power
supply. The input voltage must match the electrical input voltage shown on the
input data label on the unit nameplate. Contact the local electric utility for information
about the type of electrical service available, how proper connections should be made,
and inspection required.
The line disconnect switch provides a safe and convenient means to completely
remove all electrical power from the welding power supply whenever necessary to
inspect or service the unit.
Note
This unit is equipped with a three-conductor with earth power cable that is connected
at the welding power source end for three-phase electrical input power.
Do not connect an input (BROWN, BLUE or RED) conductor to the ground terminal.
Do not connect the ground (YELLOW/GREEN) conductor to an input line terminal.
Refer to Figure 3:
1
Connect end of ground (YELLOW/GREEN) conductor to a suitable ground.
Use a grounding method that complies with all applicable electrical codes.
2
Connect primery power cable ends; line 1, line 2 and line 3 input conductors
to the de-energized line disconnect switch.
3
Use the below table as a guide to select line fuses for the disconnect
switch.
Input Voltage
Fuse Size
3Phase 400 VAC
32 Amps
Electrical Input Connections
Note
Fuse size are based on not more than 200 percent of the rated input amperage of the
welding power source (please refer beck to the local Electrical Codes).
Figure 3.
Electrical Input Connections
12
3.05 Input Power
Note
Note the available input power. Damage to the machine could occur if 460VAC or higher
is applied.
The following 400V Primary Current recommendations are required to obtain the
maximum welding current and duty cycle from this welding equipment:
Model
Fabricator 250C III
Fabricator 320C III
Fabricator 320S III
Fabricator 400S III
Fabricator 500S III
Primary Supply
Lead Size (Factory
Fitted)
4 core 2.5mm sq
4 core 2.5mm sq
4 core 2.5mm sq
4 core 4mm sq
4 core 4mm sq
Primary Current
Circuit Size
(Vin/Amps)
400 / 14A
400 / 17.5A
400 / 17.5A
400V / 24A
400V / 43A
Max Current &
Duty Cycle
250 @ 30%
340 @ 25%
340 @ 25%
420 @ 30%
530 @ 25%
WARNING
Exceeding the duty cycle ratings will cause the thermal overload protection circuit to
become energized and shut down the output until the unit has cooled to normal
operating temperature.
CAUTION
Continually exceeding the duty cycle ratings can cause damage to the welding power
source and will void the manufactures warranty.
NOTE
Due to variations that can occur in manufactured products, claimed performance,
voltages, ratings, all capacities, measurements, dimensions and weights quoted are
approximate only. Achievable capacities and ratings in use and operation will depend
upon correct installation, use, applications, maintenance and service.
13
3.06 Specifications
FABRICATOR 250C III
FABRICATOR 320C / 320S III
Mains Input Voltage
3ph 400V 50Hz
3ph 400V 50Hz
Mains protection rating
16A slow blow
16A slow blow
Maximum power consumption
11.76 kVA
14.8 kVA
Power factor cos φ
0.9
0.9
Current range I2
40A - 250A
40A - 340A
Open circuit voltage U20
19.4 - 45.4V
18.2 - 44.9V
Welding current l2
250A
Output Voltage U2
26.5V
Welding current l2
200A
Output Voltage U2
24V
Welding current l2
170A
Output Voltage U2
22.5V
Selection range (switched steps)
10
12
Supply voltage
N/A
24Vac
Speed
1-19 m/min
1-19 m/min
Number of feed rolls
2
4
Spool + Spool weight
max 300mm + 18 kg
max 300mm + 18 kg
Dimensions H x W x D
N/A
510 x 270 x 700 mm
Protection
IP 23S
IP 23S
Insulation class
F
F
Standards
CE / EN 60 974-1 / EN 51099
CE / EN 60 974-1 / EN 51099
Weight
76kg
=
=
C 99kg S 120kg
Dimensions H x W x D (fully assembled)
800 x 380 x 870 mm
PRIMARY
SECONDARY
Duty
Cycle
30%
340A
Duty
Cycle
60%
230A
Duty
Cycle
100%
200A
31V
25.5V
24V
Duty
Cycle
20%
Duty
Cycle
60%
Duty
Cycle
100%
WIRE FEEDER
SAFETY
800 / 1360 x 380 x 870 mm
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right
to change, improve or revise the specifications or design of this or any product without prior notice.
Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the
corresponding changes, updates, improvements or replacement of such items.
14
Specifications
FABRICATOR 400S III
FABRICATOR 500S III
Mains Input Voltage
3ph 400V 50Hz
3ph 400V 50Hz
Mains protection rating
32A slow blow
32A slow blow
Maximum power consumption
16.7 kVA
28.5 kVA
Power factor cos φ
0.9
0.9
Current range I2
55A - 420A
70A - 520A
Open circuit voltage U20
19.3 - 48.0V
20.2 - 59.8V
Welding current l2
420A
InputS1 / current I1
16,7kVA/24,2A
Welding current l2
320A
InputS1 / current I1
12,4kVA/18,0A
Welding current l2
260A
InputS1 / current I1
9,5kVA/13,6A
Selection range (switched steps)
2 & 10
3 & 10
Supply voltage
24Vac
24Vac
Speed
1-19 m/min
1-25 m/min
Number of feed rolls
4
4
Spool + Spool weight
max 300 mm + 18 kg
max 300mm + 18 kg
Dimensions H x W x D
510 x 270 x 700 mm
510 x 270 x 700 mm
Protection
IP 23S
IP 23S
Insulation class
F
F
Standards
CE / EN 60 974-1 / EN 51099
CE / EN 60 974-1 / EN 51099
Weight
133kg
161kg
Dimensions H x W x D (fully assembled)
1360 x 380 x 870 mm
1430 x 440 x 870 mm
PRIMARY
SECONDARY
Duty
Cycle
30%
530A
Duty
Cycle
60%
400A
Duty
Cycle
100%
320A
25.5kVA/43.4A
16.8kVA/24.7A
12.0kVA/17.8A
Duty
Cycle
25%
Duty
Cycle
60%
Duty
Cycle
100%
WIRE FEEDER
SAFETY
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right
to change, improve or revise the specifications or design of this or any product without prior notice.
Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the
corresponding changes, updates, improvements or replacement of such items.
15
SECTION 4: OPERATOR CONTROLS
4.01 Fabricator Layout – 250C III & 320C III Compact Unit
Figure 4.
Power Source Front
Power Source Back
Power Source WFU Side
16
A1. ON/OFF Switch This switch connects the Primary supply voltage to the power
supply when in the ‘ON’ position. This enables the Power Supply.
A3. Voltage Control Switch The Voltage Control switch increases the voltage as it is
rotated in the clockwise direction. (10 position switch on the Fabricator 250C III and a
12 position switch on the 320C III)
A4. Negative Welding Terminal The negative welding current flows from the Power
Source via the heavy duty DINSE terminals to the Metal plate via an earth lead. It is
essential, that the male plug is inserted and turned securely to achieve a sound electrical
connection. (Compact 250C & 320C, maybe located in different position on front panel)
A5. Negative Welding Terminal A second negative polarity output from the Power Source
that offers two inductances of different values to the Metal plate via an earth lead. It is essential,
that the male plug is inserted and turned securely to achieve a sound electrical connection.
(Compact 320C only, maybe located in different position on front panel)
WARNING
Loose welding terminal connections can cause overheating and result in the male plug
being fused in the bayonet terminal.
A6. Control Panel see section 5.01 for further information
A7. Euro Torch Adaptor Euro torch connection that accepts Euro style MIG torches.
A8. Wire Feed Motor & Feed Roll Assembly
A9. Wire Spool Holder
A10. Gas inlet The Gas Inlet connections is a 3/8 BSP male gas fitting supplied via the
gas hose..
A11. Primary Power Cable The input cable connects the Primary supply voltage to the
equipment, see Section 3.04 for electrical input requirements.
A24. Gas Heater Outlet – An option that is not installed on this unit.
17
4.02 Fabricator Layout – 320S III & 400S III C/W VFE 4C III Wire Feed Unit
Figure 5.
Power Source Front
Power Source Back
Power Source Connection Side
Power Source WFU Side
18
A1. ON/OFF Switch This switch connects the Primary supply voltage to the power
supply when in the ‘ON’ position. This enables the Power Supply.
A2. Course Voltage Control Switch This Voltage Control switch increases the
voltage as it is rotated in the clockwise direction. (2 position switch on the Fabricator
400S III Only)
A3. Fine Voltage Control Switch The Voltage Control switch increases the voltage as it
is rotated in the clockwise direction. (10 position switch on the Fabricator 400S III and 12
position switch on the 320S III)
A4. Negative Welding Terminal The negative welding current flows from the Power
Source via the heavy duty DINSE terminals to the Metal plate via an earth lead. It is
essential, that the male plug is inserted and turned securely to achieve a sound electrical
connection. (maybe located in different position on front panel)
A5. Negative Welding Terminal A second negative polarity output from the Power Source
that offers two inductances of different values to the Metal plate via an earth lead. It is essential,
that the male plug is inserted and turned securely to achieve a sound electrical connection.
(maybe located in different position on front panel)
A6. Control Panel see section 5.01 for further information
A7. Euro Torch Adaptor Euro torch connection that accepts Euro style MIG torches.
A8. Wire Feed Motor & Feed Roll Assembly
A9. Wire Spool Holder
A10. Gas inlet The Gas Inlet connections is a 3/8 BSP male gas fitting supplied via the
gas hose on the interconnecting lead.
A11. Primary Power Cable The input cable connects the Primary supply voltage to the
equipment, see Section 3.04 for electrical input requirements.
A12. Wire Feed Holder Bolts to underside of WFU to support the WFU
A13. Wire Feed Holder Bolts to top of Power Source to support the WFU
A14. Positive Welding Terminal The Positive welding current flows from the Power
Source via the heavy duty DINSE terminals to the WFU via the interconnecting lead. It is
essential, that the male plug is inserted and turned securely to achieve a sound electrical
connection.
19
A15. Wirefeeder Control Socket outlet This Female 7 pin receptacle is used to connect
a Wirefeeder to the welding power Source circuitry: To make connections, align keyway,
insert plug, and rotate threaded collar fully clockwise. The socket information is included in
the event the supplied cable is not suitable and it is necessary to rewire a plug.
Pin 1 - 24Vac supply to WFU
Pin 2 - 0Vac
Pin 3 - Contactor return
Pin 4 - Thermal overload Signal
Pin 5 - Cooling error signal
Pin 6 - Welding volt age +
Pin 7 - Ground connection
A16. Wirefeeder Control Socket inlet, This male 7 pin receptacle is used to connect
a Wirefeeder from the welding power source circuitly.
A17. Gas inlet The Gas Inlet connections, a quick fit connector supplied via the gas
hose from the interconnecting lead.
A18. Interconnecting lead Clamp WFU
A19. Interconnecting lead Clamp Power Source
A20. Interconnecting lead inlet WFU
A21. Air Cooled Interconnecting Lead
A22. Interconnecting lead outlet Power Source
A23. Thermal Overload Indicator An indicator to inform the operator if the power
source overheats.
A24. Gas Heater Outlet – An option that is not installed on this unit.
WARNING
Loose welding terminal connections can cause overheating and result in the male plug
being fused in the bayonet terminal.
20
This page has been left blank intentionally
21
4.03 Fabricator Layout – 500S III C/W VFE 4C III Wire Feed Unit (Inc Cooler Option)
Figure 6.
Power Source Front
Power Source Back
Power Source Connection Side
Power Source WFU Side
22
A1. ON/OFF Switch This switch connects the Primary supply voltage to the power
supply when in the ‘ON’ position. This enables the Power Supply.
A2. Course Voltage Control Switch A 3 position Voltage Control switch, which increases
the voltage as it is rotated in the clockwise direction. (please ensure this switch is not turned when
the machine is under load).
A3. Fine Voltage Control Switch A 10 position Voltage Control switch increases the voltage
as it is rotated in the clockwise direction. (please ensure this switch is not turned when the machine
is under load).
A4. Negative Welding Terminals Three outlet terminals which offers negative polarity from
the Power Source via three inductances of different values through these heavy duty DINSE
terminals to the Metal plate via an earth lead. It is essential, that the male plug is inserted and
turned securely to achieve a sound electrical connection.
A6. Control Panel see section 5.01 for further information
A7. Euro Torch Adaptor Euro torch connection that accepts Euro style MIG torches.
A8. Wire Feed Motor & Feed Roll Assembly
A9. Wire Spool Holder
A10. Gas inlet The Gas Inlet connections is a 3/8 BSP male gas fitting supplied via the
gas hose on the interconnecting lead.
A11. Primary Power Cable The input cable connects the Primary supply voltage to the
equipment, see Section 3.04 for electrical input requirements.
A12. Wire Feed Holder Bolts to underside of WFU to support the WFU
A13. Wire Feed Holder Bolts to top of Power Source to support the WFU
A14. Positive Welding Terminal The Positive welding current flows from the Power
Source via the heavy duty DINSE terminals to the WFU via the interconnecting lead. It is
essential, that the male plug is inserted and turned securely to achieve a sound electrical
connection.
A15. Wirefeeder Control Socket outlet This Female 7 pin receptacle is used to connect
a Wirefeeder to the welding power Source circuitry: To make connections, align keyway,
insert plug, and rotate threaded collar fully clockwise. The socket information is included in
the event the supplied cable is not suitable and it is necessary to rewire a plug. (See
following page).
Pin 1 - 24Vac supply to WFU
Pin 2 - 0Vac
Pin 3 - Contactor return
Pin 4 - Thermal overload Signal
Pin 5 - Cooling error signal
Pin 6 - Welding voltage +
Pin 7 - Ground connection
23
A16. Wirefeeder Control Socket inlet This male 7 pin receptacle is used to connect a
Wirefeeder from the welding power source circuitly.
A17. Gas inlet The Gas Inlet connections, a quick fit connector supplied via the gas
hose from the interconnecting lead.
A18. Interconnecting lead Clamp WFU
A19. Interconnecting lead Clamp Power Source
A20. Interconnecting lead inlet WFU
A21. Water Cooled Interconnecting Lead
A22. Interconnecting lead outlet Power Source
A23. Thermal Overload Indicator An indicator to inform the operator if the power
source overheats.
A26. Quick Fit water outlet Connector Female (red) outlet Quick fit connections for
water return from a water cooled MIG torch
A27. Quick Fit water outlet Connector Female (blue) outlet Quick fit connections for
water outlet for a water cooled MIG torch
A30. Water Cooling Unit Circulates and supplies water for the water cooled Mig Torch.
See section ? for further details.
A31. Water Cooling Unit Filler Cap Remove to fill water cooling tank.
A32. Quick Fit water outlet Connector Female (red) outlet Quick fit connections for
water return from the WFU via the Interconnecting lead.
A33. Quick Fit water outlet Connector Female (blue) outlet Quick fit connections for
water supply to the WFU via the Interconnecting lead.
WARNING
Loose welding terminal connections can cause overheating and result in the male plug
being fused in the bayonet terminal.
24
SECTION 5: UNDERSTANDING & SETTING UP FOR WELDING
5.01 POWER SOURCE FEATURES
Description
FEATURES
Digital Control panel
All welding parameters are adjustable
Touch Panel Switches
Touch switches eliminates mechanical
damage
Control Knob Encoder
For the selected parameter, rotating the
knob clockwise or anticlockwise increases
or decreases the parameter.
Digital Volt and Ammeter
Displays selected weld parameter values Displays welding current when welding Displays welding voltage when welding Displays wire feed speed prior to welding
ON/OFF Switch
Primary voltage supply ON/OFF switch
located on front panel.
-
25
5.02 BASIC CONTROL PANEL - OVERVIEW
Figure 7.
Basic control panel – 250C III Compact Only
V2
Machine On/Off Switch
V4
Voltage Control Switch (250II = 10 Position switch)
V4
Voltage Control Switch (320III = 12 Position switch)
V5
Wire Speed Dial
V6
Spot Time Dial
V7
Interval Time Dial
V8
Power LED
V9
Thermal Protection LED
V10
Switch 2T/4T (optional)
V11
Wire Inch Button
V12
Gas Test Button
26
5.03 DIGITAL CONTROL PANEL – OVERVIEW
Figure 8.
Digital control panel – Compact Model shown above
Please Note: On the 320S III, 400S III & 500S III Separate the Digital Control PCB is fitted
on the separate Wire Feed Unit.
V1
V2
V3
V3
V3
V4
V4
V4
Control PCB, C/W Digital Display and Encoder
Machine ON / OFF Switch
Voltage Control Switch – Coarse (320C III = N/A)
Voltage Control Switch – Coarse (400S III = 2 position switch)
Voltage Control Switch – Coarse (500S III = 3 position switch)
Voltage Control Switch – Smooth (320S III = 12 position switch)
Voltage Control Switch – Smooth (400S III = 10 position switch)
Voltage Control Switch – Smooth (500S III = 12 position switch)
27
5.04 DIGITAL CONTROL PANEL DESCRIPTION
Figure 9.
Fig. 1 – Digital Control Panel
Pos.
X1
X2
X3
Symbol
Description
Button
 Wire inch
 Default RESET (together with button X2)
Button
 Gas test
 Default RESET (together with button X1)
Button
 Switches between 2T or 4T,
 Press & hold for 3 seconds, this will initiate spot / interval mode
 Enters secondary parameters (together with button X5)
X4
Green LED 2 Stroke
X5
Button
 Enters secondary parameters (together with button X3)
28
X8
Left Display - X8 shows:
 Amperage (real or required)
 Wire speed
 Secondary parameters:
- ISP – initial speed (soft start) [%]
- PrG – Pre gas time [s]
- PoG – Post gas time [s]
- brn – Burn back time [s]
- SPo – Time of tack welding [s]
- Int – Time of interval [s]
X9
LED - Cooling circuit error (if cooler system fitted)
X11
LED - Thermal overheating. Leave the machine on to cool down by
means of the fans.
X12
Right Display


Voltage (actual)
Values of the secondary parameters
X18
LED - 4 Stroke
X19
LED


X20
Flashes – Spot Welding mode
Illuminated – Interval welding mode
Encoder


Sets wire speed
Sets secondary parameters
29
5.05 WIRE FEEDER MOTOR & FEEDROLL ASSEMBLY
Figure 10.
Wire feed Assembles 4 rolls & 2 rolls
Pos.
E1
E2
E3
E4
E5
Description
Fixing shaft
Pressure arm
Liner- Feeder
EURO connector
Roll, Plastic cup
30
5.06 WIRE FEED ROLLERS (250C, 320C, 320S, 400S & 500S)
Grove Type
Wire Diameter
0.6 - 0.8
0.8 - 1.0
1.0 - 1.2
1.4 - 1.6
1.2 - 1.6
2.0 - 2.4
0.8 - 1.0
1.0 - 1.2
1.4 - 1.6
1.2 - 1.6
1.6 - 2.0
0.8 - 1.0
1.0 - 1.2
1.2 - 1.4
1.2 - 1.6
1.6 - 2.0
2.0 - 2.4
Figure 11.
2 Roll (30mm)
4 Roll (30mm)
250C
320C, 320S & 400S
4 Roll
(40mm)
500S
a = 22mm
B = 30mm
Item Number
2187
2188
2189
2176
2511
2512
2270
2269
2315
2316
2513
2318
2319
2320
2321
2514
2515
a = 22mm
B = 30mm
Item Number
2187
2188
2189
2176
2511
2512
2270
2269
2315
2316
2513
2318
2319
2320
2321
2514
2515
a = 32mm
B = 40mm
Item Number
1657
2150
2062
1656
1729
1842
2239
1829
2305
2313
2314
2297
2298
2299
2278
2300
2208
5.07 SPOOL HOLDER DESCRIPTION (250C, 320C, 320S, 400S & 500S)
Figure 12.
31
SECTION 6: GETTING STARTED
6.01 Torch Connection
Fit the MIG Torch (2) to the Euro adaptor (1) by pushing the torch connector into the
brass torch adaptor and screwing the plastic torch nut clockwise to secure the torch to
the torch adaptor. Remove the contact tip from the torch handset.
If a water cooled sys tem is in us e then c onnect the coolant c onnections (5) of the
torch with the sockets (3) and (4). Connect the red fitting together and the blue fittings
together.
Figure 13.
6.02 How to connect the work lead
Connect the work lead (7) to one of the two Negative connections (6) and fasten it by
turning the connector to the right. Connect the Work clamp (2 - figure 13) to the work
piece or at the welding table.
Figure 14.
6.03 Where to connect the work clamp
Fasten the Work clamp near the welding location, this avoids stray current flow
through mains earthing system.
32
Figure 15.
Connect the Work clamp tightly to the welding bench or to the work piece.
WARNING
Do not place the Work clamp on the welding machine or gas cylinder as welding
current may conducted via the mains earth and could cause the primary power cable
to burn out.
6.04 How to connect to the mains
Insert the mains plug into a suitable 3x400 V mains socket. The supply fuses or circuit
breaker should correspond to the technical data in section 3.
Switch the machine on by the main switch (Fig. 4, pos. A1)
The machine will then enter the manual program and on the left display will be the
wire speed in m/min.
6.05 How to fit the wire spool
Open the wire feed compartment lid on the machine or wire-feed case and un-screw
the nut (11) from the wire support coil hub (9).
Place wire spool on the hub (9) and ensure that the drive dog-pin (8) engages the
mating hole in the wire spool.
(located on the control panel) to adjust the
Press then release the inch switch
brake (10), the wire spool should not continue to run on when the feed motor stops.
Figure 16.
6.06 Inserting the wire
Un-screw the contact tip in the MIG torch
Open the wire feed compartment lid on the machine or wire-feed case.
Cut off the curved or damaged end of welding wire and feed it through the inlet guide
(Fig. 17, pos. 14). The diameter of the wire should correspond to the diameter of the
feedrolls. The wire size is on the face of the feedrolls.
33
Open the pressure lever (12) and thread the wire through the inlet guide (14) past the
rollers and then through the outlet guide (15).
Put the pressure roll down ensuring that the teeth of the gears fit together and fix by
setting the lever (12) into vertical position.
Adjust the pressure so that it provides constant movement. Do not over tighten
pressure arm setting as damage to motor gearbox may occur.
Figure 17.
Switch ON machine at main ON/OFF switch, stretch torch cable out straight and press
the inch button switch
on the wire feed front panel. Adjust the pressure at the
pressure adjustment screws (12) so the wire-feed rolls drive the wire consistently
without slipping. The wire should not be deformed.
Figure 18.
Adjust the pressure adjustment (12) next to the inlet guide (14) to a lower pressure
less then the pressure adjustment (12) next to the outlet guide (15), this will ensure
that the wire will be locate correctly in the wire-feed unit.
Press the inch switch
till the wire appears approximatley 20 mm out of the torch
neck. Screw in the contact tip corresponding to the wir e diameter and cut off the wire
stick out.
34
6.07 How to connect the gas cylinder
If the Power Source Wheel Kit is fitted, position a gas cylinder on the rear tray and lock
secruely to the Power Source cylinder bracket with the chains provided. If this
arrangement is not used then ensure that the gas cylinder is secured to a building pillar,
wall bracket or otherwise securely fixed in an upright position.
Open the gas valve once to blow out possible dirt particles.
Connect the gas regulator to the gas cylinder valve.
Connect the gas hose to the gas regulator.
Open the gas cylinder valve and adjust the gas flow on the gas regulator while
pressing the gas purge button
on the wire feeder control panel, The flow rate will
be shown at the flowmeter. This should be approximately wire diameter x 10 l/min.
6.08 How to configure the machine for aluminium welding
Change the feedrolls to U groove for aluminium wire.
Change the torch liner to a nylon or teflon liner.
Remove the capillary tube (23) at the central connection.
Cut the teflon liner close to the end of the feedroll and pull the brass tube over the
teflon liner with the corresponding length to stabilise it.
Fasten the torch and thread in the wire electrode.
NOTE
The parts required for the torch depends on the type torch and wire diameter. Please
refer to the torch spare list.
Figure 19.
Pos
2
19
20
21
22
23
16
Description
Central connection
Nipple for 4.0 mm and 4.7 external diameter
O-ring 3,5 x 1.5 mm to prevent gas outlet
liner nut
Nylon or Teflon liner
Support tube for nylon or teflon liner with 4 mm OD, it substitute the outlet
guide in the central connection (16). A 4.7 mm diameter liner does not
require the support tube is required.
Feedroll
35
SECTION 7: OPERATION
7.01 Setting welding current and voltage
When the wire had been installed and gas had been set it is possible to start welding.
The appliance must be plugged into the mains, the main switch (Fig. 4, Page 16) in the
"I" position, and the green LED will illuminate.
To select the voltage use step switches (Fig. 4, Page 16).
To select the current (that is linked to the wire speed) use potentiometer encoder (Fig.
7, Page 16).
7.02 Welding modes
The Fabricator torch operator controls work in four modes:
• Continuous two stroke (2T)
• Continuous four stroke (4T)
• Spot welding
• Interval welding
7.03 Secondary parameters
If necessary, it is possible to change the secondary parameters:
Initial wire speed (soft start)
Pre gas time
Post gas time
Burn back time
Time of spots (tack or interval welding)
Time of intervals (interval welding)
ISP
PrG
PoG
brn
SPo
Int
Press buttons 3 and 5 at the same time for at least (3s)
On left display will appear ISP. On the right display will appear value of the chosen
parameter.
By means of the Encoder you can change the parameter.
to select the next parameter. When you press the button 3, the
Use the button 3
value of the previous parameter had been stored.
36
7.04 Two stroke
(2T/4T) and select the LED 4
. Welding procedure starts
Press the button 3
by pressing the button in the torch handle. It is necessary to keep the torch button
pressed all the time during welding. The welding stops by releasing the torch button.
1 - 1st stroke – pressing the torch button
Figure 20.
2 - 2nd stroke – releasing the torch button
7.05 Four stroke
(2T/4T ) and select the LED 4
The four stroke mode is
Press the button 3
being used mostly for long welds, when there is no need to hold the torch button
pressed. The welding procedure start by pressing the torch button; after releasing the
torch button the welding continues. The welding stops after the second pressing and
releasing the torch button then.
Figure 21.
1 - 1st stroke – pressing the torch button
3 - 3rd stroke – pressing the torch button
2 - 2nd stroke – releasing the torch button
4 - 4th stroke – releasing the torch button
37
7.06 Spot and stitch welding
Keep pressing the button 3 for at least (3s)
(2T/4T)
If led LED 12
continuously lights the spot mode has been selected. If led 12
flashes the interval mode has been selected.
You can have spot or interval welding both in stroke and in 4 stroke mode (by means
of short pressing the button 3
- LEDs 4
and 11
indicate the mode.
To get out of this mode, keep pressing the button '3' for more than 3 seconds.
The spot welding mode is being used for welding short welds of the same length. The
pressing the torch button activates the time circuit that starts and end the welding
procedure. This mode is available in 2T or 4T mode.
1
- 1st stroke – pressing the torch button
1
- 1st stroke – pressing the torch button
2
Figure 22.
- 2nd stroke – releasing
The interval welding mode is being used for welding repeated short welds of the same
length of welding time and the pause time. By pressing the torch button activate the
time circuit that starts and end the welding procedure. This mode is available in 2T or
4T mode.
2
38
Figure 23.
- 2nd stroke – releasing the torch button
SECTION 8: BASIC WELDING TECHNIQUE
8.01 Setting of the Fabricator
The Fabricators Power Source has two control settings that have to balance. These are
the Wirespeed control and the Voltage Control switches. The welding current is
determined by the Wirespeed control, the current will increase with increased
Wirespeed, resulting in a shorter arc. Less wire speed will reduce the current and
lengthen the arc. Increasing the welding voltage hardly alters the welding current level,
but lengthens the arc. By decreasing the voltage, a shorter arc is obtained with little
change in welding current.
When changing to a different electrode wire diameter, different control settings are
required, a thinner electrode wire needs more Wirespeed to achieve the same current
level.
A satisfactory weld cannot be obtained if the wirespeed and voltage switch settings
are not adjusted to suit the electrode wire diameter and dimensions of the work piece.
If the Wirespeed is too high for the welding voltage, “stubbing” will occur as the wire
dips into the molten pool and does not melt. Welding in these conditions normally
produces a poor weld due to lack of fusion. If, however, the welding voltage is too
high, large drops will form on the end of the electrode wire, causing spatter. The
correct setting of voltage and Wirespeed can be seen in the shape of the weld deposit
and heard by a smooth regular arc sound.
8.02 Position of MIG Torch
MIG torch angle to the weld has an effect on the width of the weld run. Refer to figure
17.
Figure 24.
8.03 Distance of the MIG Torch Nozzle to the Work Piece
The electrode stick out from the MIG Torch nozzle should be between 2.0mm (5/64”)
and 5.0mm. (13/64”) This distance may vary depending on the type of joint that is being
welded.
8.04 Travel Speed
Speed at which a weld travels influences the width of the weld and penetration of the
welding run.
8.05 Electrode Wire Size Selection
The choice of electrode wire size in conjunction with shielding gas used depends on:
a) Thickness of the metal to be welded,
b) Type of joint,
39
c) Capacity of the wire feed unit and Power Source,
d) The amount of penetration required,
e) The deposition rate required,
f) The bead profile desired,
g) The position of welding and
h) Cost of the electrode wire.
Weld metal deposition rate is proportional to current density. Current density is defined
as the current per cross sectional area of the electrode wire and is normally expressed
as amps per mm2. An example is tabled below.
Electrode Wire
Current Density
Deposition Rate
Current (Amps)
Size
(Amps/mm2)
(kg/hour)
0.9mm (.035”)
200
314
3.2
1.2mm (.045”)
200
177
2.8
The table above - 0.9mm (.035”) / 1.2mm (.045”) wire deposition rate
This demonstrates that where the upper limit of current is limited by machine capacity
and duty cycle, higher deposition rates and therefore greater productivity will be
achieved by using smaller electrode wire. The Fabricator is a particularly efficient MIG
welder with 0.9mm steel wire in spray tranfer mode.
Higher current density (or smaller diameter wire) also gives deeper penetration as
shown Figure 25.
0.9 mm (.035")
1.2mm (.045")
Figure 25.
Penetration comparison using the same current (200A) for both electrodes Figure 25 Wire penetration comparison
8.06 Stitch Welding Operation
Stitch welding is normally used to bridge excessive gaps between panels or when
welding very thin material to prevent heat build up and distortion.
Please refer to section 7.06 for Stitch function control.
8.07 Spot Welding Operation
Fit a spot welding nozzle to the MIG Torch for consistent spot welding operations.
The Fabricator will operate effectively using 0.8mm welding wire when
spot welding. Penetration depth is limited when using 0.6mm welding wire for
spot welding.
Please refer to section 7.06 for Spot welding control.
40
SECTION 9: ROUTINE MAINTENANCE & INSPECTION
The only routine maintenance required for the Fabricator range of machines is a
thorough cleaning and inspection, with the frequency depending on the usage and the
operating environment.
WARNING
Disconnect the FABRICATOR from the Mains supply voltage before disassembling.
Special maintenance is not necessary for the control unit parts in the Power Source
and Wirefeeder. If these parts are damaged for any reason, replacement is
recommended.
CAUTION
Do not blow air into the Power Source / Wirefeeder during cleaning. Blowing air into
the Power Source / Wirefeeder can cause metal particles to interfere with sensitive
electronic components and cause damage to the Power Source / Wirefeeder.
To clean the Power Source / Wirefeeder, disconnect it from the mains supply voltage
then open the enclosure and use a vacuum cleaner to remove any accumulated dirt
and dust. The Power Source / Wirefeeder should also be wiped clean. If necessary,
solvents that are recommended for cleaning electrical apparatus may be used.
WARNING
Do not attempt to diagnose or repair unless you have had training in electronic
measurement and troubleshooting techniques.
Troubleshooting and repairing of the Fabricator III range of welding equipment should
only be carried out only by suitably qualified or competent person.
A ‘competent person’ must be a person who has acquired through training, qualification
or experience, or a combination of them, the knowledge and skills enabling that person
to safely carry out a risk assessment and repairs to the electrical equipment in question.
The person carrying out the servicing needs and repairs must know what to look at, what
to look for and what to do.
41
SECTION 10: BASIC TROUBLESHOOTING
Basic level of troubleshooting is that which can be performed without special
equipment or knowledge, and without removing the covers from the Power Source /
Wirefeeder.
If major components are faulty, then the Power Source / Wirefeeder should be
returned to your local THERMAL ARC Distributor for repair.
Solving Problems beyond the Welding Terminals
The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at
the wire spool then work through to the MIG torch. There are two main areas where
problems occur with MIG Equipment:10.01 Porosity
When there is a gas problem the result is usually porosity within the weld metal.
Porosity always stems from some contaminant within the molten weld pool which is in
the process of escaping during solidification of the molten metal.
Contaminants range from no gas around the welding arc to dirt on the work piece
surface. Porosity can be reduced by checking the following points:
1
Gas cylinder contents and flow
Ensure that the gas cylinder is not empty
meter.
and the flow meter is correctly adjusted to
15 litres per minute.
2
Gas leaks
Check for gas leaks between the
regulator/cylinder connection and in the
gas hose to the Power Source.
3
Internal gas hose in the Power
Ensure the hose from the solenoid valve
to Source. The Mig torch adaptor has not
fractured and that it is connected to the
Mig torch adaptor.
4
Welding in a windy environment.
5
Welding dirty, oily, painted,
oxidised or greasy plate.
6
Distance between the MIG torch
nozzle and the work piece
Maintain the MIG torch in good
working order
7
Shield the weld area from the wind or
increase the gas flow.
Clean contaminates off the plate
Keep the distance between the MIG torch
nozzle and the work piece to a minimum.
Ensure that the gas holes are not
blocked. and gas is exiting out of the
torch nozzle.
Do not restrict gas flow by allowing
spatter to build up inside the Mig torch
nozzle.
Check that the MIG torch O-rings are not
damaged
WARNING
DISENGAGE THE DRIVE ROLL WHEN TESTING FOR GAS FLOW BY EAR.
42
10.02 Inconsistent wire feed
Wire feeding problems can be reduced by checking the following points:
1
Wire spool brake is too tight
Feed roller driven by motor in the cabinet
will slip.
2
Wire spool brake is too loose
Wire spool can unwind and tangle.
3
Worn or incorrect feed roller size
Use 'U' groove drive feed roller matched
to the aluminium wire size you are
welding.
Use 'V' groove drive feed roller matched
to the steel wire size you are welding.
Use ‘knurled V’ groove drive feed roller
matched to the flux cored wire size you
are welding.
4
Mis-alignment of inlet/outlet guides Wire will rub against the mis-aligned
guides and reduces wire feedability.
5
Liner blocked with swarf
Swarf is produced by the wire passing
through the feed roller, if excessive
pressure is applied to the pressure roller
adjuster.
Swarf can also be produced by the wire
passing through an incorrect feed roller
groove shape or size.
Swarf is fed into the liner where it
accumulates thus reducing wire
feedability
6
Incorrect or worn contact tip
The contact tip transfers the weld current
to the electrode wire. If the hole in the
contact tip is to large then arcing may
occur inside the contact tip resulting in
the electrode wire jamming in the contact
tip
When using soft electrode wire such as
aluminium it may become jammed in the
contact tip due to expansion of the wire
when heated. A contact tip designed for
soft electrode wires should be used.
7
Poor work lead contact to work
If the work lead has a poor electrical
piece
contact to the work piece then the
connection point will heat up and result in
a reduction of power at the arc.
8
Bent or Mis-Shaped liner
This will cause friction between the wire
and the liner thus reducing wire
feedability
43
10.03 Welding Problems
FAULT
Undercut.
CAUSE
A. Welding arc voltage
too high.
B. Incorrect torch angle
C. Excessive heat input
REMEDY
A. Reduce voltage by reducing
the voltage selection switches
position or increase the wire
feed speed.
B. Adjust angle
C. Increase the torch travel
speed and/or reduce welding
current by reducing the voltage
selection switches position or
reducing the wire feed speed.
2
Lack of
penetration.
A. Welding current too
low
B. Joint preparation too
narrow or gap too tight
C. Shielding gas
incorrect
A. Increase welding current by
increasing wire feed speed
and increasing voltage
selection switch position.
B. Increase joint angle or gap
C. Change to a gas which
gives higher penetration
3
Lack of fusion.
Voltage too low
4
Excessive spatter.
A. Voltage too high
B. Voltage too low
Increase voltage by increasing
voltage selection switches
position.
A. Lower voltage by reducing
the voltage selection switches
or increase wirespeed control.
B. Raise voltage by increasing
the voltage selection switches
or reduce wirespeed control.
5
Irregular weld
shape.
A. Incorrect voltage and
current settings.
Convex, voltage too low.
Concave, voltage too
high.
B. Wire is wandering
C. Incorrect shielding
gas
D. Insufficient or
excessive heat input
1
44
A. Adjust voltage and current
by adjusting the voltage
selection switches and the
wirespeed control.
B. Replace contact tip
C. Check shielding gas.
D. Adjust the wirespeed
control or the voltage selection
switches.
10.03
Welding Problems (continued)
6
FAULT
Weld cracking.
CAUSE
A. Weld beads too small
B. Weld penetration
narrow and deep
C. Excessive weld
stresses
D. Excessive voltage
E. Cooling rate too fast
7
Cold weld puddle.
A. Faulty rectifier unit
B. Loose welding cable
connection.
C. Low Primary Voltage
8
Arc does not have
a crisp sound that
short arc exhibits
when the wirefeed
speed and voltage
are adjusted
correctly.
The MIG torch has been
connected to the wrong
voltage polarity on the
front panel.
10.04
1
2
3
REMEDY
A. Decrease travel speed
B. Reduce current and voltage
and increase Mig torch travel
speed or select a lower
penetration shielding gas.
C. Increase weld metal
strength or revise design
D. Decrease voltage by
reducing the voltage selection
switches.
E. Slow the cooling rate by
preheating part to be welded
or cool slowly.
A. Have an Accredited
THERMAL ARC Service Agent
to test then replace the faulty
component.
B. Check all welding cable
connections.
C. Contact supply authority
Connect the MIG torch to the
positive (+) welding terminal
for solid wires and gas
shielded flux cored wires.
Refer to the electrode wire
manufacturer for the correct
polarity.
Power Source Problems
FAULT
Indicator light is
ON but welding
arc can not be
established.
Mains supply
voltage is ON.
Indicator light is
not lit and welding
arc can not be
established.
Mains indicator
light is not lit but
welding arc can be
established.
CAUSE
Voltage switch in
standby position.
A. Primary fuse is
blown.
B. Broken connection in
primary circuit.
Indicator light is open
circuit.
45
REMEDY
Switch the voltage selection
switches to a welding
setting.
A Replace primary fuse. Have
B an Accredited THERMAL
ARC Service Agent check
primary circuit.
Have an Accredited
THERMAL ARC Service
Agent replace Indicator
light.
10.04 Power Source Problems (continued)
FAULT
CAUSE
4 Mains supply voltage is Torch trigger switch
ON and Indicator light is leads are disconnected.
lit but when the torch
trigger switch is
depressed nothing
happens.
REMEDY
Reconnect.
5 Mains supply voltage is
ON, no wire feed but gas
flows from the MIG Torch
when the torch trigger
switch is depressed.
A. Electrode wire stuck
in conduit liner or
contact tip (burn-back
jam).
B. Faulty control PCB
A. Check for clogged / kinked
MIG Torch conduit or worn
contract tip. Replace faulty
component(s).
B. Have an Accredited
THERMAL ARC Service Agent
investigate the fault.
6 Wire feeds when the
torch trigger switch is
depressed but arc can
not be established.
Poor or no work lead
connection.
Clean work clamp area and
ensure good electrical contact.
7 Wire continues to feed
when the torch trigger
switch is released.
The Mode Selection has
been set to 4T (latch
operation).
Set the Mode Selector Switch
has been set to 2T (normal
operation).
8 Jerky wire feed
A. Worn or dirty contact
tip
B. Worn feed roll.
C. Excessive back
tension from wire reel
hub.
D. Worn, kinked or dirty
conduit liner
A. Gas hose is cut.
B. Gas passage
contains impurities.
C. Gas regulator turned
off.
A. Replace contact tip
B. Replace feed roll
C. Reduce brake tension on
spool hub
D. Clean or replace conduit
liner
Gas valve has jammed
open due to impurities in
the gas or the gas line.
Have an Accredited
THERMAL ARC Service Agent
repair or replace gas valve.
9 No gas flow
10 Gas flow continues
after the torch trigger
switch has been
released.
46
A Replace or repair.
B Disconnect gas hose from
the rear of FABRICATOR or
wirefeeder then raise gas
pressure and blow out the
impurities.
C Turn on.
This page has been left blank intentionally
47
SECTION 11: SPARE PARTS
11.01 Parts Description Fabricator 250C & 320C
Figure 26.
48
11.01 Spare Part Numbers Fabricator 250C & 320C
Pos Item No Title Quantity Thermal Arc 250C III & 320C III 1 FABV20214‐5A Facia panel 1 2 FABV0316 Corner Right 1 3 FABV0317 Corner Left 1 4 FABV10014‐2 Corner support right galvanized 1 5 FABV10015‐2 Corner support left galvanized 1 6 FABV20219‐2 PCB cover galvanized 1 7 FABV20001‐7 Bottom galvanized 1 8 FABV20232‐6 Rear panel galvanized 1 9 FABV20004‐9 Support vertical galvanized 1 10 FABV20002‐7 Support horizontally galvanized 1 11 FABV20008‐3A Cover upper matt 1 13 FAB2557 Solenoid Valve 24V 50Hz AC 1 14 FABV10231‐2 Fan shutter galvanized 1 15 FABV10007‐3B Side cover (Door) right upper 1 16 FABV10237‐2 Holder gas bottle galvanized 1 17 FABV0318 Feeder Cover Plastic 1 18 FAB1627 Spool Holder Black 1 19 FABK910 Adapter up to 18 kg 2 20 FABV20206‐3B Side cover left 1 21 FABV20210‐3B Side cover right lower 1 22 FABV20216‐5B Front panel Analog 250C matt 1 22 FABV20213‐4B Front panel Digital 320C matt 1 23 FAB3598 Handle ‐ Holder Left 1 24 FAB3599 Handle ‐ Holder Right 1 25 FABV10552‐1A Handle bar matt 9005 1 26 FABV0005‐3B Carriage unit matt 9005 1 27 FAB2523‐1 Choke 250 1 27 FAB4164 Choke 320 1 28 FAB1005 Switch ON/OFF 1 29 FAB2626 Switch VS16 250/400 1 29 FAB3678 Switch VS16 320 1 30 FAB805.3342 Outlet PG11 1 31 FABBG‐90625,3440 Connector EURO Body 1 32 FABAO‐20610 Dinse Connector 35‐70 Panel Socket 2 33 FAB276834 Contactor (24V/50Hz) 250 1 33 FAB277008 Contactor (24V/50Hz) 320 1 34 FAB3270‐4Z Transformer Aux (with filter) 1 35 L93322 Control PC Board ‐ BASIC 1 35 FAB3979.d Control PC Board ‐ DIGITAL 1 36 FAB3505 Film Front 1 49
Thermal Arc 250C III & 320C III (Continued) 37 FAB2164 Knob + Red Cap 1 38 FAB2446 Rear wheel 2 39 FAB3253‐1 Front Wheel 2 40 FAb2681 Door Lock 2 41 FAB4121 Door Hinge 2 42 FAB1812 Gas heater connector 1 43 FAB2917 Shunt 400A 60mV 2 44 FAB4316 Wire Feed Motor C/W Gearbox 2 roll 250C 1 44 FAB4322‐1 Wire Feed Motor C/W Gearbox 4 roll 320C 1 45 FAB467434/467594 Cover for PG36/Nut for PG 36 1 46 FABV20005‐3 Holder of ventilator 250 galvanized 1 46 FABV20006‐2 Holder of ventilator 320 galvanized 1 47 FAB4172 Fan 250 & 320 2 48 FABT25.TERP Transformer 250 + Switch + TERMINAL 1 48 FABT32WSK.TERP Transformer 320 + Switch + TERMINAL 1 49 FAB1195‐1 Rectifier 250 1 49 FAB1538‐1 Rectifier 320 1 50 FABV20009‐1 Holder of choke galvanized 2 51 FABV20215‐3 Support of facia panel galvanized 1 52 FABV20010‐3 Holder of rectifier 250‐320 galvanized 1 61 FAB4263 Knob arrow 250 RED 3 61 FAB1343 Knob arrow 320 RED 3 62 FAB4262 Knob arrow 250 Black 1 62 FAB2015 Knob arrow 320 Black 1 63 FAB4236 Filter FC 61113 1 64 FAB3252 Filter FZ 730 43 3 65 FAB302P010000 Gas Hose 1 66 FABVM0313 Cables 250 (Quick Connector 12mm) 1 66 FABVM0348 FABVM0049 Cables 320C 1 67 Mains Cable 16A 4x1.5mm 250 1 67 FABVM0048 Mains Cable 4x2.5mm 320/400 1 68 FABVS040258 Chain 70 cm 2 50
11.02 Parts Description Fabricator 320S & 400S
Figure 27.
51
11.02 Spare Part Numbers Fabricator 320S & 400S
Pos Item No Title Quantity Thermal Arc 320S III & 400S III 1 FABV20214‐5A Facia panel matt 1 2 FABV0316 Corner Right 1 3 FABV0317 Corner Left 1 4 FABV10014‐2 Corner support right galvanized 1 5 FABV10015‐2 Corner support left galvanized 1 6 FABV20219‐2 PCB cover galvanized 1 7 FABV20001‐7 Bottom galvanized 1 8 9 FABV20232‐6 FABVA2004‐14 Rear panel galvanized Support vertical galvanized 1 10 FABVA2002‐12 Support horizontal galvanized 1 11 FABV20008‐3A Cover upper MATT 1 14 Fan shutter rear galvanized Lateral cover right upper gloss 1 15 FABV10231‐2 FABV20208‐1B 1 16 FABV10237‐2 Holder gas bottle galvanized 1 20 FABV20206‐3B Lateral cover left 1 21 FABV20210‐3B FABV20217‐9B Lateral cover right lower Front panel matt 1 22 22 FABV20221‐3B Front panel Digital RAL matt 9005 1 23 FAB3598 Handle ‐ Holder L 1 24 FAB3599 Handle ‐ Holder R 1 25 FABV10552‐1A Handle bar matt 1 26 FABV0005‐3B Carriage unit matt 1 27 FAB4164 Choke ALF 320S/400S 1 28 FAB1005 Switch ON/OFF 320S 1 28 FAB1005‐2 Switch ON/OFF 400S 1 29 FAB2626 Switch VS16 250/400 1 29 FAB3678 Switch VS16 320 1 30 FAB805.3342 Outlet PG11 1 32 FABAO‐20610 Quick Connector 35‐70 Panel Socket 2 33 FAB277008 Contactor 320S 1 33 FAB1250034900 Contactor 400S 1 34 FAB3270‐4Z Transformer AUX with filter 1 38 FAB2446 Rear wheel 2 39 FAB3253‐1 Front Wheel 2 43 FAB2917 Shunt 400A 60mV 2 46 FABV20005‐3 Holder of ventilator galvanized 1 46 FABV20006‐2 Holder of ventilator galvanized 1 47 FAB4172 Fan 320S 2 47 FAB3624 Fan 400S/500S 2 48 FABT32WSK.TERP Transformer 320S + Switch + TERMINAL 1 52
1 1 Thermal Arc 320S III & 400S III (Continued) 48 FABT40WSK.TERP Transformer 400S + Switch + TERMINAL 49 FAB1538‐1 Rectifier 320S & 400S 1 50 FABV20009‐1 Holder of choke galvanized 2 51 FABV20215‐3 Support of facia panel galvanized 1 52 FABV20010‐3 Holder of rectifier 320S & 400S galvanized 1 53 FABVS040372 Clamp for the cable Bundle 1 55 FAB3467B Wire Feed holder 1 56 FABAO‐20610 Quick Connector 35‐70 Panel Socket 1 57 FABVM0344 Bundle clamp 1 58 FAB2115 Diode LED 10mm green 1 59 FAB4298 Packing 6.35‐38mm 1 60 FAB2036 Switch VS16 400S 1 61 FAB4263 Knob arrow 34mm/6 red 400S 3 61 FAB1343 Knob arrow OM‐R/5 Red 320S 3 62 FAB4262 Knob arrow 34mm/6 Black 400S 1 62 FAB2015 Knob arrow OM‐C/5 Black 320S 1 63 FAB4236 Filter FC 61113 + R 64 FAB3252 Filter FZ 730 43 65 FAB302P010000 Gas hose 66 FABVM0348 Cables 320S 66 FABVM0349 FABVM0048 Cables 400S 67 68 FABVS040258 Chain 70 cm 1 3 1 1 1 1 2 Mains Cable 4x2.5mm 320/400 53
11.03 VFE 4C III Wire Feed Unit Parts Description + Spare Part Numbers
Figure 28.
Pos Item No Title VF E4C III Wire feed unit Quantity 1 FABV10001‐5 Bottom galvanized WFU 1 2 FABV10019‐2 PCB cover galvanized WFU 1 3 FABV10004‐6 Barrier of connectors galvanized 1 4 FABV10002‐3 Cover upper PS matt 1 5 FABV10006‐4 Cover left Gloss 1 6 FABV10007‐4 Cover right Gloss 1 7 FABVA0011‐4A Facia panel matt 1 8 FABVA0004‐15 Support vertical compact galvanized 1 9 FABV10013‐3A Front panel matt 1 10 FABV0316 Corner Right 1 11 12 FABV10014‐2 FABV0317 Corner support right galvanized Corner Left 1 1 13 FABV10015‐2 FABV0318 Corner support left galvanized Feeder Cover Plastic 1 1 14 54
VF E4C III Wire feed unit (Continued) 15 FAB2927 Front Wheel 2 16 FAB2928 Rear Wheel 2 17 FAB4220 Handle 1 18 FAB4322‐1 Feed Motor / Gearbox (VF E4C III Fab 320S/400S) 1 19 FAB302P010000 Gas hose 20 FABV9040157.Y Cables PS4W mont. cas. 0.34m 70mm DIGITAL 1 21 FAB2557 Solenoid Valve 24V 50Hz AC 1 22 FAB7.686.300 Door Lock 2 23 FAB4121 Door Hinge 2 24 FABVM0112.YQ Bundle PS.Y DIGITAL 1 25 FABBG‐90625 Connector EURO Body 1 26 FAB3979.d Control PC Board ‐ Digital 1 27 FAB3505 Film PCB PANEL 1 28 FAB2917‐1 Shunt 400A 60mV 1 29 FAB3467A Feeder holder 1 30 FABVS040372 Clamp for the cable Bundle 1 31 FAB4476 Knob 25,0 2004‐2 Without and arrow, Without a Line 1 32 FAB711P001206 Connector TKB 50‐70 1 33 FAB3598 Handle ‐ Holder L 1 34 FAB3599 Handle ‐ Holder R 1 35 FAB1627 Spool Holder Standard 2 (30 kg) 1 36 FAB3440 Cover Connector EURO Body 1 0.75 55
11.04 Parts Description Fabricator 500S
Figure 29.
56
11.04 Spare Part Numbers Fabricator 500S
Pos Item No Title Quantity Thermal Arc 500S III 1 FABVA0237‐6A Facia panel matt 1 2 FABV0316 Corner Right 1 3 FABV0317 Corner Left 1 4 FABV10014‐4 Corner support right galvanized 1 5 FABV10015‐4 Corner support left galvanized 1 6 FABV10219‐4 PCB cover galvanized 1 7 FABVA0201‐6 Bottom galvanized 1 8 FABVA0232‐10 Rear panel galvanized 1 9 FABVA2238‐5 Support vertical galvanized 1 10 FABVA0202‐6A Cover upper matt 1 11 FABV10231‐3 Fan shutter galvanized 1 12 FABV30209‐1B Lateral cover right upper gloss 1 13 Holder gas bottle matt Lateral cover left gloss 2 14 FABV10237‐3A FABV30206‐4B 15 FABV30210‐6B Lateral cover right lower gloss 1 16 FABV30220‐6A Front panel Generator matt 1 18 FAB3598 Handle ‐ Holder L 1 19 FAB3599 Handle ‐ Holder R 1 20 FABV10551‐4N Handle bar galvanized 1 21 Carriage compact matt Choke 500S 1 22 FABV10300‐1A FAB4273 23 FABVM0353 Switch VS16 ON/OFF 1 25 FAB2631‐1 Switch 500S FINE 1 26 FAB1831‐1 Switch 500S COARSE 1 30 FAB2549 Outlet GP16 1 31 FABAO‐20610 Quick Connector 35‐70 Panel Socket 4 32 FAB1336000100 Contactor 500S 1 33 FAB3293 Terminal board 1916 1 35 FAB4142‐1Z Aux Transformer with filter 1 36 FAB4122 Rear wheel 2 37 FAB3254‐1 Front Front Wheel 2 40 FABV30204‐5 Holder of ventilator galvanized 1 42 FAB3624 Fan 400S/500S 2 51 FABT51WSK.TERP Transformer 500S + Switch + TERMINAL 1 53 FAB2671‐1 Rectifier 500S 1 54 FABV10235‐4 Support of front eye galvanized 1 56 FABV10234‐4 Support of facia panel galvanized 1 57 58 FABV30211‐2 FABVS040372 Holder of rectifier galvanized Clamp for the cable Bundle 1 1 59 FAB3467B Wire Feed holder 1 60 FABV30230‐3 Cover galvanized 1 57
1 1 Thermal Arc 500S III (Continued) 61 FABVM0364 Bundle Generator 1 62 FAB2073 LED Sleeve 10mm RTF‐1090 1 63 FAB4298 Packing HP208/6,35‐38mm 1 66 FAB1343 Knob arrow OM‐R/5 Red 1 67 FAB1141 Knob arrow OS‐C/6 Black 2 68 FAB4236 Filter FC 61113 + R 1 69 FAB3252 Filter FZ 730 43 3 71 FABVM0370 Cables 500S 1 76 FABVM0104 Mains Cable 4x4mm 1 78 FABVS040258 Chain 70 cm 2 80 FAB4458 81 FAB3235 82 FAB3260 83 FAB3234 Bushing 2879 RSA4 clip RSA4 White Clamp White 1 1 1 2 58
11.05 VFE 4C HS III Wire Feed Unit Parts Description + Spare Part Numbers
Figure 30.
Pos Item No Title VF E4C III Wire feed unit 1 FABV10001‐5 Bottom galvanized WFU 1 2 FABV10019‐2 PCB cover galvanized WFU 1 3 FABV10004‐6 Barrier of connectors galvanized 1 4 FABV10002‐3 Cover upper PS matt 1 5 FABV10006‐4 Cover left Gloss 1 6 FABV10007‐4 Cover right Gloss 1 7 FABVA0011‐4A Facia panel matt 1 8 FABVA0004‐15 Support vertical compact galvanized 1 9 FABV10013‐3A Front panel matt 1 10 FABV0316 Corner Right 1 11 FABV10014‐2 Corner support right galvanized 1 12 FABV0317 Corner Left 1 13 FABV10015‐2 Corner support left galvanized 1 59
Quantity 14 FABV0318 VF E4C III Wire feed unit (Continued) Feeder Cover Plastic 1 15 FAB2927 Front Wheel 2 16 FAB2928 Rear Wheel 2 17 FAB4220 Handle 1 18 FAB4322‐1 Feed Motor / Gearbox (VF E4C III Fab 320S/400S) 19 FAB302P010000 Gas hose 1 20 FABV9040157.Y Cables PS4W mont. cas. 0.34m 70mm DIGITAL 1 21 FAB2557 Solenoid Valve 24V 50Hz AC 1 22 FAB7.686.300 Door Lock 2 23 FAB4121 Door Hinge 2 24 FABVM0112.YQ Bundle PS.Y DIGITAL 1 25 FABBG‐90625 Connector EURO Body 1 26 FAB3979.d Control PCB 1 27 FAB3505 Film PCB PANEL 1 28 FAB2917‐1 Shunt 400A 60mV 1 29 FAB3467A Feeder holder 1 30 FABVS040372 Clamp for the cable Bundle 1 31 FAB4476 Knob 25,0 2004‐2 Without and arrow, Without a Line 1 32 FAB711P001206 Connector TKB 50‐70 1 33 FAB3598 Handle ‐ Holder L 1 34 FAB3599 Handle ‐ Holder R 1 35 FAB1627 Spool Holder Standard 2 (30 kg) 1 36 FAB3440 Cover Connector EURO Body 1 0.75 60
11.06 Water Cooler Parts Description + Spare Part Numbers
Figure 31.
Pos Item No Title Cooler for 500S III 1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 FABV10241‐6 FABV10503‐4 FABV10243‐7A FABV10245‐6A FAB2457 FABVM0373 FAB4172 FAB4131 FAB2546 FAB3490 FABVS040375 FABVS040376 FAB4260 FABVM0371 FABV9040040 FAB2705 FAB0545002 FABBD‐80225 Body Panel galvanized Holder of ventilator galvanized Cover matt Cover upper matt Pump MTP‐600 with plastic cover Tank Water cooling Fan 500S Cooler Heat Exchanger Clamp 8‐12 Fitting GES 8/R 1/4 Adaptor FEMALE for flow sensor FL‐2000 Adaptor MALE for flow sensor FL‐2000 Flow sensor FL‐2000 Hose Set Cable clamp S12 Film PLEXI 140x50mm; 1,5mm Profile A1010 6x9mm Water Quick Connector 10mm 1 18 FABVM0400 Fixing Kit for fitting to 500S Quantity 61
1 1 1 1 1 1 1 10 2 1 1 1 1 1 1 0.1 2 1 SECTION 12: MACHINE SCHEMATICS
12.01 Power Source Schematic Fabricator 250C III & 320C III
Figure 32.
62
12.02 Power Source Schematic Fabricator 320S III & 400S III
Figure 33.
63
12.03 Power Source Schematic Fabricator 500S III
Figure 34.
64
12.04 Wire Feed Unit Schematic (VFE 4C III & VFE 4C HS III WFU)
Figure 35.
65
SECTION 13:
OPTIONAL ACCESSORIES
Part No
Description
A.028E
Water Cooler c/w fittings (500S Only)
VM0391E
VM0393E
VM0394E
1.6M Interconnecting Cable Assy (air Cooled) 320S
5M Interconnecting Cable Assy (air Cooled) 320S
10M Interconnecting Cable Assy (air Cooled) 320S
VM0263E
VM0266E
VM0267E
1.6M Interconnecting Cable Assy (air Cooled) 400S/500S
5M Interconnecting Cable Assy (air Cooled) 400S/500S
10M Interconnecting Cable Assy (air Cooled) 400S/500S
VM0264E
VM0265E
VM0268E
1.6M Interconnecting Cable Assy (Water Cooled) 500S
5M Interconnecting Cable Assy (Water Cooled) 500S
10M Interconnecting Cable Assy (Water Cooled) 500S
Feed Rolls for Fabricator 250C/320C/320S/400S:
2187
2189
2511
2269
2316
2513
2319
2321
0.6/0.8mm
1.0/1.2mm
1.2/1.6mm
10/1.2mm
1.2/1.6mm
1.6/2.0mm
1.0/1.2mm
1.2/1.6mm
Hard Wire V Groove Feed Roll
Hard Wire V Groove Feed Roll
Hard Wire V Groove Feed Roll
Soft Wire U Groove Feed Roll
Soft Wire U Groove Feed Roll
Soft Wire U Groove Feed Roll
Cored Wire V Groove Feed Roll
Cored Wire V Groove Feed Roll
Feed Rolls for Fabricator 500S:
1657
2062
1729
1829
2313
2314
2298
2278
0.6/0.8mm
1.0/1.2mm
1.2/1.6mm
10/1.2mm
1.2/1.6mm
1.6/2.0mm
1.0/1.2mm
1.2/1.6mm
Hard Wire V Groove Feed Roll
Hard Wire V Groove Feed Roll
Hard Wire V Groove Feed Roll
Soft Wire U Groove Feed Roll
Soft Wire U Groove Feed Roll
Soft Wire U Groove Feed Roll
Cored Wire V Groove Feed Roll
Cored Wire V Groove Feed Roll
2 Roll Drive = 250C
4 Roll Drive = 320C/320S/400S/500S
66
This page has been left blank intentionally
67
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
FAX:
(636) 728-3010
Email: [email protected]
www.thermalarc.com